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Bard WG241 Installation Instructions Manual

Other manuals for WG241: Installation Instructions Manual
Manual is about: WG-SERIES COMBINATION GAS/ELECTRIC WALL-MOUNT

Summary of WG241

  • Page 1

    Warning read all instructions carefully before beginning the installation. The installation must comply with these instructions and the requirements of all governing codes and ordinances for the installation location. It is the responsibility of installer to know and understand all of these requirem...

  • Page 2: Contents

    Contents getting other information and publications .............. 1 wg series model nomenclature............................... 2 ventilation options .................................................... 2 air conditioning module options ............................... 3 1. Important ..................

  • Page 3: Contents

    Contents figures figure 1 unit dimensions ..................................... 6 figure 2 mounting instructions – wg24-36 ......... 9 figure 2a mounting instructions – wg42-60 ....... 10 figure 3 combustible clearance – wg24-36 ..... 11 figure 3a combustible clearnace – wg42-60 ..... 11 figure 4 wa...

  • Page 4

    Manual 2100-365k page 1 getting other information and publications for more information, contact these publishers: acca air conditioning contractors of america 1712 new hampshire avenue, nw washington, dc 20009 telephone: (202) 483-9370 ansi american national standards institute 11 west street, 13th...

  • Page 5

    Manual 2100-365k page 2 wg 42 1 – a x c x x x x x x wall mount gas/electric general model number nomenclature 1 low ambient control is required with economizer for low temperature compressor operation ventilation options s l e d o m 6 3 g w , 0 3 g w , 4 2 g w 0 6 g w , 8 4 g w , 2 4 g w n o i t p i...

  • Page 6: Caution

    Manual 2100-365k page 3 1. Important the equipment covered in this manual is to be installed by trained, experienced service and installation technicians. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensa...

  • Page 7

    Manual 2100-365k page 4 table 1 specifications wg24, wg 30 and wg36 models * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker s n oi t a ci fi c e p s l e d o ma - 1 4 2 g wb - 1 4 2 g wc - 1 4 2 g wa - 1 0 3 g wb - 1 0 3 g wc - 1 0 3 g wa - 1 6 3 g wb - 1 6 3 g w...

  • Page 8

    Manual 2100-365k page 5 * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker table 1a specifications wg42, wg48 and wg60 models s n oi t a ci fi c e p s l e d o ma - 2 2 4 g wb - 2 2 4 g wc - 2 2 4 g wa - 1 8 4 g wb - 1 8 4 g wc - 1 8 4 g wa - 1 0 6 g wb - 1 0 6 g w...

  • Page 9

    Manual 2100-365k page 6 f g n p d dd ff gg hh a m i c k j l h r s s s s s t v y aa x u z cc bb b ee o e w ii q b gas entrances low voltage entrances condenser air inlet condenser air outlets 4 deg. Pitch in top vestibule door service/filter hinged door combustion air exhaust combustion air intake co...

  • Page 10: Warning

    Manual 2100-365k page 7 see figure 3 and clearance information in section 9 and table 2 for additional information. Design the duct work according to methods given by the air conditioning contractors of america (acca). When duct runs through unheated spaces, it should be insulated with a minimum of ...

  • Page 11: Caution

    Manual 2100-365k page 8 7. Wall mounting information 1. Two holes for the supply and return air openings must be cut through the wall as detailed in figure 4. 2. On wood-frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit v...

  • Page 12

    Manual 2100-365k page 9 figure 2 mounting instructions for wg24, wg30, and wg36 39 3/16" 29 3/4" 4 11/16" 12" 12" 12" 12" 12" 12" 2" 2 1/4" 10" 28 5/16" 15" 27" 17 15/16" 11 5/16" 8 5/8" 2 15/16" 2 1/4" 30" 29" 5 1/16" 7/16" 5 9/16" 4 9/16" 4 1/2" 2 15/16" 18 15/16" 4 9/16" supply air duct return ai...

  • Page 13

    Manual 2100-365k page 10 figure 2a mounting instructions for wg42, wg48, and wg60

  • Page 14: Warning

    Manual 2100-365k page 11 figure 3 combustible clearance for wg24, wg30 and wg36 models figure 3a combustible clearance for wg42, wg48 and wg60 models warning a minimum of one (1) inch clearance must be maintained between the supply air duct and combustible materials. This is required for the first t...

  • Page 15

    Manual 2100-365k page 12 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 16

    Manual 2100-365k page 13 figure 6 common wall mounting installations.

  • Page 17: Warning

    Manual 2100-365k page 14 9. Clearances minimum clearances, as specified in table 2, must be maintained from adjacent structures to provide adequate fire protection, adequate combustion air, and room for service personnel. While minimum clearances are acceptable for safety reasons, they may not allow...

  • Page 18: Caution

    Manual 2100-365k page 15 10. Vent terminal and combustion air inlet hood the vent terminal is shipped in the burner compartment. See figure 7. Remove the two shipping screws and separate the two-piece assembly. Install the vent terminal by using the four screws provided. Make sure gasket is in place...

  • Page 19

    Manual 2100-365k page 16 12. Vent resizing instructions when an existing furnace is removed from a venting system servicing other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following steps shall be followed with each of the applia...

  • Page 20: Warning

    Manual 2100-365k page 17 electrical grounding when installed, the furnace must be electrically grounded in accordance with local codes or in the absence of local codes, with the national electrical code, ansi/nfpa 70, or canadian electrical code, csa22.1, latest edition. Use a copper wire from green...

  • Page 21

    Manual 2100-365k page 18 note: the voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). P a t e g n a r 0 4 2 6 1 2 - - 3 5 2 8 0 2 7 8 1 - - 0 2 2 17. Thermostats 16. Wiring – low voltage wiri...

  • Page 22

    Manual 2100-365k page 19 figure 11 low voltage wiring.

  • Page 23

    Manual 2100-365k page 20 figure 12 gas pipe connection.

  • Page 24

    Manual 2100-365k page 21 8. Refer to table 6 for gas pipe sizes for natural gas. If more than one appliance is supplied from a single line size, capacity must equal or exceed the combined input to all appliances, and the branch lines feeding the individual appliances properly sized for each input. 1...

  • Page 25: Warning

    Manual 2100-365k page 22 19. Manifold pressure adjustment you will need a 0 to 15 inch water manometer with 0.1 inch resolution and a 1/8" npt manual shut off valve to measure actual manifold pressure. Depending on your local gas heating value and elevation, you may need to adjust manifold pressure ...

  • Page 26: Warning

    Manual 2100-365k page 23 natural gas input rate natural gas heating value (btu/cu. Ft.) can vary significantly. Before starting natural gas input check, obtain gas heating value at your location from local supplier. You will need a stopwatch to measure actual gas input. 1. Gas supply pressure must b...

  • Page 27

    Manual 2100-365k page 24 21. Standard orifice sizing and high altitude derate this furnace is shipped with fixed gas orifices for use with natural gas and sized for 1000 btu/cubic foot gas. Make sure actual gas input does not exceed rating plate input. You may need to change orifices to get correct ...

  • Page 28

    Manual 2100-365k page 25 all other orifice sizes shown are available as individual items. See orifice charts below for part numbers and number required. Table 8 natural gas orifice tables for models wg24, wg30 and wg36 y r o t c a f d r a d n a t s t u p n i e u l a v * t a e h s a g . T f . U c / u...

  • Page 29

    Manual 2100-365k page 26 all other orifice sizes shown are available as individual items. See orifice charts on page 25 for part numbers and number required. Table 8a natural gas orifice tables for models wg42, wg48 and wg60 y r o t c a f d r a d n a t s t u p n i * t a e h s a g e u l a v . T f . U...

  • Page 30: Warning

    Manual 2100-365k page 27 23. Measuring air temperature rise air temperature rise (supply air temperature minus return air temperature) must be within allowable air temperature rise range specified on furnace rating plate and in table 1. You will need 2 thermometers with 1 degree resolution capable o...

  • Page 31

    Manual 2100-365k page 28 24. Filters a 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the main service door. (see figure 14.) replacement filters are available through your dealer. 25. Compressor control module the compressor control is an anti-short cycle/...

  • Page 32

    Manual 2100-365k page 29 adjustments adjustable delay-on-make and delay-on-break timer the potentiometer is used to select delay-on-break time from 30 seconds to 5 minutes. Delay-on-make (dom) timing on power-up and after power interruptions is equal to 2 minutes plus 10% of delay- on-break (dob) se...

  • Page 33

    Manual 2100-365k page 30 26. Lighting and shutdown instructions figure 15 instruction label.

  • Page 34: Warning

    Manual 2100-365k page 31 27. Service agency procedures main burner observe the main burners in operation. The flame should be mostly “blue” with possibly a little orange (not yellow) at the tips of the flame. The flames should be in the center of the heat exchanger tubes and not impinging on the hea...

  • Page 35: Warning

    Manual 2100-365k page 32 routine maintenance 1. Air filters – check the condition at least monthly when the unit is in use, and replace as necessary. 2. Lubrication requirements – the indoor circulating air blower motor and outdoor circulating air fan motor are permanently lubricated and require no ...

  • Page 36

    Manual 2100-365k page 33 30. Sequence of operation – heating on a call for heat from the thermostat, the induced draft blower is energized. Once sufficient draft is established, the pressure switch contacts close and the ignition system is energized. The direct spark ignitor will be energized allowi...

  • Page 37

    Manual 2100-365k page 34 32. Indoor blower operation all models have multiple speed direct drive blower motors. If supply and return ducts are connected to the unit, the ducts must be of adequate size. Refer to the appropriate blower tables. See tables 10, 11, 12, 13, 14 and 15 for maximum static pr...

  • Page 38

    Manual 2100-365k page 35 figure 19 460 volt blower motor wiring options wg24, wg30 and wg36 models.

  • Page 39

    Manual 2100-365k page 36 figure 20 460 volt blower motor wiring options wg42, wg48 and wg 60 models.

  • Page 40

    Manual 2100-365k page 37 table 10 wg241 indoor blower performance @ 230 and 460 volts recommended wg241 cooling airflow range at rated 800 cfm @ 0.15 esp (wc) is 680 - 920 cfm factory set on low speed for cooling and high for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt dehum...

  • Page 41

    Manual 2100-365k page 38 table 11 wg301 indoor blower performance @ 230 and 460 volts recommended wg301 cooling airflow range at rated 1000 cfm @ 0.35 esp (wc) is 820 - 1150 cfm factory set on medium speed for cooling and for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt dehum...

  • Page 42

    Manual 2100-365k page 39 table 12 wg361 indoor blower performance @ 230 and 460 volts recommended wg361 cooling airflow range at rated 1100 cfm @ 0.250 esp (wc) is 935 - 1265 cfm factory set on medium speed for cooling and for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt dehu...

  • Page 43

    Manual 2100-365k page 40 table 13 wg422 indoor blower performance @ 230 and 460 volts recommended wg422 cooling airflow range at rated 1300 cfm @ .35 esp (wc) is 1500 - 1030 cfm factory set on medium speed for heating and cooling voltage adjustment – reduce airflow by 130 cfm for 208 volt top outlet...

  • Page 44

    Manual 2100-365k page 41 table 14 wg481 indoor blower performance @ 230 and 460 volts recommended wg481 cooling airflow range at rated 1550 cfm @ .38 esp (wc) is 1750 - 1280 cfm factory set on high speed for cooling and medium speed for heating. Voltage adjustment – reduce airflow by 130 cfm for 208...

  • Page 45

    Manual 2100-365k page 42 table 15 wg601 indoor blower performance @ 230 and 460 volts recommended wg601 cooling airflow range at rated 1650 cfm @ .30 esp (wc) is 1910 - 1340 cfm factory set on high speed for cooling and medium speed for heating. Voltage adjustment – reduce airflow by 130 cfm for 208...

  • Page 46

    Manual 2100-365k page 43 table 16 integrated furnace and blower control operation l o r t n o c e c n e u q e s n o i t i n g i e c r u o s n o i t i n g i i s d c a v 4 2 g n i s n e s e m a l f e t o m e r s g n i m i t - - - - - - - - - - - - - - e g r u p e r p e g r u p t s o p e g r u p l a i ...

  • Page 47

    Manual 2100-365k page 44 33. Pressure service ports high and low pressure service ports are installed on all units so that the system operating pressures can be observed. Table 17 outlines expected pressures at various indoor and outdoor temperatures. Low side pressure ± 2 psig high side pressure ± ...

  • Page 48: * *

    Manual 2100-365k page 45 34. Refrigerant charge the correct system r-22 charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6" from compressor) as shown in table 18. The suction line temperatures in table 18...

  • Page 49

    Manual 2100-365k page 46 index wiring diagrams and ladder diagrams t i n u . O n l e d o m c i s a b m a r g a i d g n i r i w l a u n a m . O n e g a p c i s a b m a r g a i d r e d d a l l a u n a m . O n e g a p a - 1 4 2 g w b 2 3 1 - 5 8 0 4 7 4 b 1 2 1 - 5 8 0 4 8 4 b - 1 4 2 g w b 2 3 2 - 5 8...

  • Page 50

    Manual 2100-365k page 47 wg241-a 230/208-60-1.

  • Page 51

    Manual 2100-365k page 48 wg241-a 230/208-60-1.

  • Page 52

    Manual 2100-365k page 49 wg241-b 230/208-60-3.

  • Page 53

    Manual 2100-365k page 50 wg241-b 230/208-60-3.

  • Page 54

    Manual 2100-365k page 51 wg241-c 460-60-3.

  • Page 55

    Manual 2100-365k page 52 wg241-c 460-60-3.

  • Page 56

    Manual 2100-365k page 53 wg301-a, wg361-a 230/208-60-1.

  • Page 57

    Manual 2100-365k page 54 wg301-a, wg361-a 230/208-60-1.

  • Page 58

    Manual 2100-365k page 55 wg301-b, wg361-b 230/208-60-3.

  • Page 59

    Manual 2100-365k page 56 wg301-b, wg361-b 230/208-60-3.

  • Page 60

    Manual 2100-365k page 57 wg301-c, wg361-c 460-60-3.

  • Page 61

    Manual 2100-365k page 58 wg301-c, wg361-c 460-60-3.

  • Page 62

    Manual 2100-365k page 59 wg422-a 230/208-60-1.

  • Page 63

    Manual 2100-365k page 60 wg422-a 230/208-60-1.

  • Page 64

    Manual 2100-365k page 61 wg422-b 230/208-60-3.

  • Page 65

    Manual 2100-365k page 62 wg422-b 230/208-60-3.

  • Page 66

    Manual 2100-365k page 63 wg422-c 460-60-3.

  • Page 67

    Manual 2100-365k page 64 wg422-c 460-60-3.

  • Page 68

    Manual 2100-365k page 65 wg481-a, wg601-a 230/208-60-1.

  • Page 69

    Manual 2100-365k page 66 wg481-a, wg601-a 230/208-60-1.

  • Page 70

    Manual 2100-365k page 67 wg481-b, wg601-b 230/208-60-3.

  • Page 71

    Manual 2100-365k page 68 wg481-b, wg601-b 230/208-60-3.

  • Page 72

    Manual 2100-365k page 69 wg481-c, wg601-c 460-60-3.

  • Page 73

    Manual 2100-365k page 70 wg481-c, wg601-c 460-60-3.